Aliphatic polycarbonate homo-and co-polymers produced by DMC catalysis and the process for their production

ABSTRACT

Aliphatic polycarbonate homo- and co-polymers are obtained by ring-opening homo- or co-polymerization of cyclic carbonates by DMC catalysis. These polymers are useful in the production of polyurethanes.

BACKGROUND OF THE INVENTION

[0001] The invention relates to aliphatic polycarbonate homo- andco-polymers which are obtained by ring-opening homo- orco-polymerization of cyclic carbonates by DMC catalysis.

[0002] Double metal cyanide (DMC) catalysts useful for the ring-openingpolymerization of oxygen-containing, cyclic monomers have been known fora long time. DMC catalysts are of particular commercial interest for theproduction of polyether polyols by polyaddition of epoxides to startercompounds exhibiting active hydrogen atoms (See, e.g., U.S. Pat. Nos.3,404,109; 3,829,505; 3,941,849 and 5,158,922.) because the use of a DMCcatalyst reduces the proportion of monofunctional polyethers withterminal double bonds (so-called “mono-ols”) compared to polyetherpolyols produced using conventional alkaline catalysts. Moreover,improved, highly active DMC catalysts, which are described, e.g., inU.S. Pat. No. 5,470,813; EP-A 700 949; EP-A743 093; EP-A 761 708; WO97/40086; WO 98/16310 and WO 00/47649, possess extraordinarily highactivity and permit polyether polyol production at very low catalystconcentrations (25 ppm or less). Consequently, it is no longer necessaryto separate the catalyst from the finished product. In addition, DMCcatalysts also make possible the homo- and co-polymerization of otheroxygen-containing, cyclic monomers, such as oxetanes, (U.S. Pat. Nos.3,278,457 and 3,404,109), cyclic anhydrides (U.S. Pat. Nos. 5,145,883and 3,538,043) and lactones (U.S. Pat. No. 5,032,671).

[0003] Aliphatic polycarbonate homo- and co-polymers are suitable asadditives for thermoplastic systems. Moreover, aliphatic, OH-functionalpolycarbonates are widely used as a hydroxyl component for building uppolyurethanes and polyurethane-urea elastomers. Common methods for theproduction of aliphatic polycarbonates are transesterification of a diolwith a dialkyl carbonate from a short-chain alcohol, with a dioxolanoneor with a diphenyl carbonate. These reactions are accelerated bycatalysts, particularly alkali, tin and titanium compounds (See, e.g.,Kunststoffhandbuch, vol. 3/1 Polycarbonate, Hanser Verlag, Munich, 1992,p. 118f.).

SUMMARY OF THE INVENTION

[0004] It has now been found that aliphatic polycarbonate homo- andco-polymers can be obtained by ring-opening homo- or co-polymerizationof a cyclic carbonate by DMC catalysis.

DETAILED DESCRIPTION OF THE INVENTION

[0005] The present invention relates to aliphatic polycarbonate homo-and co-polymers, which are obtained entirely or partly by ring-openinghomo- or co-polymerization of cyclic carbonates by DMC catalysis.

[0006] Suitable cyclic carbonates useful in the practice of the presentinvention may be represented by the general formula (I.) or (II.)

[0007] in which

[0008] m, n, p and q, independently of one another, each represents 0,1, 2, 3, 4, or 6 and

[0009] R¹ and R² represent H, a C₁₋₆ alkyl, a C₃₋₆ alkenyl, or a C₁₆alk(en)yloxy-C₁₋₆ alkyl group, particularly H, CH₃ and C₂H₅.

[0010] Preferred cyclic carbonates represented by formula (I) or (II)include: trimethylene glycol carbonate, neopentyl glycol carbonate,1,4-butanediol carbonate and dimeric carbonates of pentanediol or ofhexanediol. Particularly preferred are 6-membered ring carbonates,particularly neopentyl glycol carbonate.

[0011] Suitable DMC catalysts are known and are described in detail inthe disclosures discussed in the Background of the Invention. Improved,highly active DMC catalysts, such as those described in U.S. Pat. No.5,470,813; EP-A 700 949; EP-A 743 093; EP-A 761 708; WO 97/40086; WO98/16310 and WO 00/47649, are preferably used. The highly active DMCcatalysts described in EP-A 700 949, which, in addition to a doublemetal cyanide compound (e.g. zinc hexacyano-cobaltate(III)) and anorganic complex ligand (e.g. tert.-butanol), also contain a polyetherwith a number-average molecular weight of more than 500 g/mole, aretypical examples of suitable catalysts.

[0012] The DMC-catalyzed, ring-opening homo- or co-polymerization of thecyclic carbonate generally takes place at temperatures of from 20 to200° C., preferably in the range of from 40 to 180° C., most preferablyat temperatures of from 80 to 160° C. The reaction can be conductedunder a total pressure of from 0.001 to 20 bar. The polymerization canbe performed in substance or in an inert, organic solvent, such astoluene or tetrohydrofuran (THF). If used, the quantity of solvent isgenerally from 10 to 30 wt. %, based on the total amount of polymer tobe produced.

[0013] The catalyst concentration is generally in the range of from0.0005 wt. % to 1 wt. %, preferably in the range of from 0.001 wt. % to0.1 wt. %, most preferably in the range of from 0.001 to 0.05 wt. %,based on the total amount of polymer to be produced.

[0014] The polymerization can be performed continuously ornon-continuously, e.g. in a batch or semi-batch process.

[0015] The DMC-catalyzed, ring-opening homo- or co-polymerization of thecyclic carbonate is optionally performed in the presence of one or morestarter compounds exhibiting active hydrogen atoms. In this way,OH-functionalized aliphatic polycarbonate homo- and co-polymers that aresuitable as polyol components for building up polyurethane systems canbe produced.

[0016] Compounds with molecular weights of from 18 to 10,000 g/mole andhaving from 1 to 8 hydroxyl groups are preferably used as startercompounds exhibiting active hydrogen atoms. Examples of such compoundsinclude: water, ethanol, butanol, ethylene glycol, diethylene glycol,triethylene glycol, 1,2-propylene glycol, 1,4-butanediol, hexamethyleneglycol, bisphenol A, trimethylolpropane, glycerol, pentaerythritol,sorbitol, cane sugar, degraded starch, polyether polyols and polyesterpolyols.

[0017] The DMC-catalyzed, ring-opening polymerization of the cycliccarbonate can be performed as a homo-polymerization, optionally in thepresence of one or more starter compounds exhibiting active hydrogenatoms.

[0018] The DMC-catalyzed, ring-opening polymerization of the cycliccarbonates can also be performed as a co-polymerization, againoptionally in the presence of one or more starter compounds exhibitingactive hydrogen atoms. Both random co-polymerization and blockco-polymerization are possible.

[0019] In random co-polymerization, the DMC-catalyzed, ring-openingpolymerization of the cyclic carbonate is performed in the presence ofone or more other monomers suitable for polymerization with a DMCcatalyst. Particularly suitable for random co-polymerization with cycliccarbonates are: epoxides, particularly ethylene oxide, propylene oxideand butylene oxide and mixtures thereof; oxetanes; cyclic anhydrides,such as phthalic anhydride; cyclic esters, such as caprolactone; andlactides.

[0020] In the production of polycarbonate block co-polymers inaccordance with the present invention, the aliphatic polycarbonate blockis obtained by means of DMC-catalyzed, ring-opening polymerization of acyclic carbonate. Preferred block co-polymers include:poly(ester-block-carbonate) co-polymers and poly(ether-block-carbonate)co-polymers, in which the ester or ether block can be obtained by any ofthe known processes or catalysts.

[0021] In a preferred embodiment of the process of the presentinvention, a polyether polyol is first produced by any of the knownmethods, e.g., by DMC-catalyzed polyaddition of an epoxide,(particularly propylene oxide and/or a propylene oxide/ethylene oxidemixture), to the starter compound exhibiting active hydrogen atoms(mentioned above). The polyether polyol containing the active DMCcatalyst is then reacted with a cyclic carbonate in the manner accordingto the present invention, with ring-opening. In this reaction with thecarbonate, secondary hydroxyl groups of the polyether polyol can beconverted completely or partially into primary hydroxyl groups, whichare more reactive with isocyanate groups. These poly(ether-carbonate)polyols are therefore of great interest for use in the production ofpolyurethanes.

[0022] Having thus described the invention, the following Examples aregiven as being illustrative thereof.

EXAMPLES Example 1

[0023] In a heatable, flat-ground jar equipped with a stirrer and refluxcondenser, 20 g of a polypropylene glycol starter compound(number-average molecular weight =1,000 g/mole) and 4 mg of DMC catalyst(containing zinc hexacyanocobaltate, tert.-butanol and polypropyleneglycol with a number-average molecular weight of 1000 g/mole; describedin EP-A 700 949) were placed under argon and heated to 105° C. 20 g ofpropylene oxide were then metered in continuously at 105° C. undernormal pressure within 3 hours. When all of the propylene oxide had beenadded, 5.2 g of neopentyl glycol carbonate were added and stirring wasthen continued for 1 hour at 150° C. under normal pressure. Volatilecomponents were then distilled off for 1 h at 150° C./1 mbar. Themixture was then cooled to ambient temperature.

[0024] A slightly yellowish, clear product was obtained. ¹H- and ¹³C-NMRanalysis showed that 28% of the secondary hydroxyl groups of thepolypropylene glycol had reacted with neopentyl glycol carbonate, withring opening, forming a primary hydroxyl group.

Example 2

[0025] In a heatable, flat-ground jar equipped with a stirrer and refluxcondenser, 20 g of a polypropylene glycol starter compound(number-average molecular weight =1,000 g/mole) and 2 mg of the DMCcatalyst used in Example 1 were placed under argon and heated to 105° C.20 g of propylene oxide were then metered in continuously at 105° C.under normal pressure within 3 hours. When all of the propylene oxidehad been added, 5.2 g of neopentyl glycol carbonate were added andstirring was then continued for 5 hours at 150° C. under normalpressure. Volatile components were then distilled off for 1 h at 150°C./1 mbar and the reaction mixture was then cooled to ambienttemperature.

[0026] A yellowish, clear product was obtained. ¹H- and ¹³C-NMR analysisshowed that 47% of the secondary hydroxyl groups of the polypropyleneglycol had reacted with neopentyl glycol carbonate, with ring opening,forming a primary hydroxyl group.

Example 3

[0027] In a heatable, flat-ground jar equipped with a stirrer and refluxcondenser, 20 g of a polypropylene glycol starter compound(number-average molecular weight=1,000 g/mole) and 2 mg of the DMCcatalyst used in Example 1 were placed under argon and heated to 105° C.20 g of propylene oxide were then metered in continuously at 105° C.under normal pressure over 3 hours. When all the propylene oxide hadbeen added, 15.6 g of neopentyl glycol carbonate were added and stirringwas then continued for 1 hour at 150° C. under normal pressure. Volatilecomponents were then distilled off for 1 h at 150° C./1 mbar and thereaction mixture was then cooled to ambient temperature.

[0028] A yellowish and (because of unreacted neopentyl glycol carbonate)cloudy product was obtained. ¹H- and ¹³C-NMR analysis showed that 70% ofthe secondary hydroxyl groups of the polypropylene glycol had reactedwith neopentyl glycol carbonate, with ring opening, forming a primaryhydroxyl group.

[0029] Although the invention has been described in detail in theforegoing for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be limited by the claims.

What is claimed is:
 1. An aliphatic polycarbonate polymer produced by ring-opening polymerization of a cyclic carbonate in the presence of a DMC catalyst.
 2. The aliphatic polycarbonate polymer of claim 1 in which the cyclic carbonate is represented by general formula (I) or (II)

in which m, n, p and q, independently of one another, represent 0, 1, 2,3, 4,5 or 6 and R¹ and R² represent H, a C₁₋₆ alkyl, a C₃₋₆ alkenyl, or a C₁₋₆ alk(en)yloxy-C₁₋₆ alkyl group.
 3. The aliphatic polycarbonate polymer of claim 1 in which the cyclic carbonate is neopentyl glycol carbonate.
 4. The aliphatic polycarbonate polymer of claim 1 in which the DMC catalyst used to produce the polymer contains zinc hexacyanocobaltate(III).
 5. The aliphatic polycarbonate polymer of claim 1 in which the DMC catalyst used to produce the polymer contains tert.-butanol.
 6. The aliphatic polycarbonate polymer of claim 1 in which the ring-opening polymerization is performed in the presence of one or more starter compounds exhibiting active hydrogen atoms.
 7. A process for the production of a polyol comprising ring-opening a cyclic carbonate in the presence of a DMC catalyst.
 8. A process for the production of a poly(ether-carbonate) polyol comprising a) producing a polyether polyol by polyaddition of an epoxide to a starter compound exhibiting active hydrogen atoms in the presence of a DMC catalyst and b) reacting the polyether polyol containing the active DMC catalyst with a cyclic carbonate under conditions such that ring-opening in the cyclic carbonate occurs.
 9. The poly(ether-carbonate) polyol produced by the process of claim
 8. 10. A polyurethane produced by reacting the polyol of claim 9 with an isocyanate. 